Sterile adapters with a shifting plate for use in a robotic surgical system

Abstract

Generally, a sterile adapter for use in robotic surgery may include a frame configured to be interposed between a tool driver and a surgical tool, a plate assembly coupled to the frame, and at least one rotatable coupler supported by the plate assembly and configured to communicate torque from an output drive of the tool driver to an input drive of the surgical tool.

The invention claimed is: 
     
       1. A sterile adapter for use in a robotic surgical system, the sterile adapter comprising:
 a frame configured to be interposed between a tool driver and a surgical tool; 
 a plate assembly coupled to the frame and comprising a plurality of tool engagement features, wherein the plurality of tool engagement features have a varying size and are arranged according to an increase in the varying size along a longitudinal axis of the sterile adapter and each tool engagement feature is mateable with a corresponding adapter engagement feature on the surgical tool; and 
 at least one rotatable coupler supported by the plate assembly and configured to communicate torque from an output drive of the tool driver to an input drive of the surgical tool; 
 wherein the frame is configured to couple to the surgical tool when each tool engagement feature is mated with its corresponding adapter engagement feature on the surgical tool. 
 
     
     
       2. The sterile adapter of  claim 1 , wherein the varying size comprises a width dimension or a length dimension, and the tool engagement features are arranged in a sequential series according to an increasing width dimension or an increasing length dimension on the plate assembly. 
     
     
       3. The sterile adapter of  claim 2 , wherein at least one tool engagement feature comprises an elongated portion arranged transverse to the longitudinal axis. 
     
     
       4. The sterile adapter of  claim 2 , wherein the varying size comprises varying lengths and the tool engagement features are arranged in a sequential series according to length. 
     
     
       5. The sterile adapter of  claim 1 , wherein the frame defines a generally planar opening and the plate assembly is movable within the opening. 
     
     
       6. The sterile adapter of  claim 5 , wherein the plate assembly is movable between a first position in which the rotatable coupler is disengaged with the input drive of the surgical tool and a second position in which the rotatable coupler is engaged with the input drive of the surgical tool. 
     
     
       7. The sterile adapter of  claim 6 , wherein the plate assembly is configured to be in the second position when each tool engagement feature is mated with its corresponding adapter engagement feature on the surgical tool. 
     
     
       8. The sterile adapter of  claim 5 , wherein the plate assembly comprises at least one spring configured to urge at least a portion of the plate assembly toward the surgical tool. 
     
     
       9. The sterile adapter of  claim 1 , wherein the surgical tool is configured to deliver a longitudinal force directed along a longitudinal axis of the sterile adapter and wherein the plate assembly comprises at least one abutment configured to transmit the longitudinal force to the tool driver. 
     
     
       10. A sterile adapter for use in a robotic surgical system, the sterile adapter comprising:
 a frame configured to be interposed between a tool driver and a surgical tool, wherein the surgical tool is configured to deliver a longitudinal force directed along a longitudinal axis of the sterile adapter; 
 a plate assembly coupled to the frame and comprising at least one elongated abutment that extends in a direction transverse to the longitudinal axis and configured to transmit the longitudinal force to the tool driver; and 
 at least one rotatable coupler supported by the plate assembly and configured to communicate torque from an output drive of the tool driver to an input drive of the surgical tool. 
 
     
     
       11. The sterile adapter of  claim 10 , wherein the abutment includes an outward projection configured to extend into a surface of the tool driver. 
     
     
       12. The sterile adapter of  claim 10 , wherein the abutment is angled along the longitudinal axis of the sterile adapter. 
     
     
       13. The sterile adapter of  claim 10 , wherein the abutment is a recess wall configured to receive a feature on a surface of the tool driver. 
     
     
       14. The sterile adapter of  claim 10 , wherein the plate assembly comprises a plurality of tool engagement features arranged transverse to the longitudinal axis of the sterile adapter, wherein each tool engagement is mateable with a corresponding adapter engagement feature on a surgical tool. 
     
     
       15. The sterile adapter of  claim 14 , wherein the abutment is disposed on a first face of the plate assembly and at least one of the tool engagement features is disposed on a second face of the plate assembly opposite the first face, and wherein the abutment and the at least one tool engagement feature are substantially aligned. 
     
     
       16. A sterile adapter for use in a robotic surgical system, the sterile adapter comprising:
 a frame configured to be interposed between a tool driver and a surgical tool; 
 a plate assembly coupled to the frame and having a first face and a second face opposite the first face, wherein the first face comprises at least one spring that is configured to bias the second face toward the surgical tool by pushing off a sterile adapter-facing surface of the tool driver; and 
 at least one rotatable coupler supported by the plate assembly and configured to communicate torque from an output drive of the tool driver to an input drive of the surgical tool. 
 
     
     
       17. The sterile adapter of  claim 16 , wherein the spring is integrally formed with at least a portion of the plate assembly. 
     
     
       18. The sterile adapter of  claim 17 , wherein the spring comprises a biased member extending from the first face of the plate assembly. 
     
     
       19. The sterile adapter of  claim 16 , wherein the first face of the plate assembly comprises a plurality of springs arranged in a bilaterally symmetrical arrangement. 
     
     
       20. The sterile adapter of  claim 16 , wherein the surgical tool is configured to deliver a longitudinal force directed along a longitudinal axis of the sterile adapter and wherein the plate assembly comprises at least one abutment configured to transmit the longitudinal force to the tool driver.